Champion Power Equipment C50079 User manual

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C50079 5,000lb Winch
Owners Manual
INTRODUCTION
Congratulations on your purchase of a Champion Power Equipment winch. CPE
designs and builds winches to strict specifications and with proper use and
maintenance should bring you years of satisfying service.
READ, STUDY, AND FOLLOW ALL INSTRUCTIONS BEFORE
OPERATING THIS DEVICE.
Your winch can develop tremendous pulling forces and if used unsafely or
improperly could result in property damage, serious injury, or death. Throughout
this manual you will find the following symbols for caution, warning, and danger.
Pay particular attention to the notes preceded by these symbols as they are written
for your safety. Ultimately, safe operation of this device rests with you, the
operator.
Indicates a potentially hazardous situation which, if not avoided, may
result in minor or moderate injury. This notation is also used to alert
against unsafe practices.
Indicates a potentially hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION
WARNING
WARNING

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CONTENTS
This carton contains the following items, please unpack carefully.
Read Instructions before beginning.
DESCRIPTION QUANTITY
Winch assembly with wire cable 1
Power Cord/Switch Assembly 1
CapBoltM10x35 6
LockWashers 6
FlatWashers 6
M10Nuts 6
ClevisHookw/Pin 1
HandStrap 1

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GETTING TO KNOW YOUR WINCH
Your 5,000lb Champion Power Equipment winch is a powerful piece of machinery. It
is important that you understand the basics of its operation and specifications so
that when you need to use it, you can use it with confidence and safety. Below is a
list of the components of your winch and their uses. Practice operating your winch
before you actually use it.
1. Motor: Your 1.8HP motor requires a 650CCA 12 volt battery for operation and
provides power to the gear mechanism which turns the drum and winds the
wire cable.
2. Winch Drum: The winch drum is the cylinder on which the wire cable is
stored. It can feed or wind the rope depending on the remote winch switch.
3. Wire Rope: Your winch has a 1/4” x 79’ galvanized aircraft cable designed
specifically for load capacity of 5,000lbs. The wire cable feeds onto the drum
in the “under wind” position and is looped at the end to accept the clevis
hook pin.
4. Planetary Gear System: The reduction gears convert the winch motor power
into extreme pulling forces. This system allows high torque while even
though it is light weight and compact.
5. Braking System: Braking action is automatically applied to the winch drum
when the winch motor is stopped and there is a load on the wire rope. The
braking action is applied by a separate mechanical brake.
6. Free Spooling Clutch: The clutch allows the operator to manually disengage
(“Out”) the spooling drum from the gear train. Engaging the clutch (“In”)
locks the winch into the gear system.
7. Solenoid: Power from the vehicle battery flows through the weather seared
solenoid switch before being directed to the winch motor.
8. Remote Switch: Power switch with 12’ cord has a dual switch for powering
the rope in or out of your winch drum. The 12’ cord allows you to stand clear
of the wire rope when the winch is under load.

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9. Clevis Hook: This hook allows you to connect the winch to the object you are
pulling.
FIG B

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MOUNTING YOUR WINCH
(Mounting Channel and Roller Fairlead not included)
1. Your CPE 5,000lb winch is designed with a 6.55” x 4.5” bolt pattern that is
standard in this class of winch. Winch mounting kits are available that utilize
this bolt pattern for most popular trucks, SUV’s, and ATV’s. If you cannot find
a kit locally, contact CPE and we will provide you with the name of a dealer
near you.
If you will utilize a mounting channel you must ensure that it is
mounted on a flat surface so that the three major sections (motor, drum and
gear housing) are properly aligned. Proper alignment of the winch will allow
even distribution of the full rated load.
2. Insert 2xM10 Nuts with Lock Washers (Part# 500022 & Part # 500020) to the
mounting channel (not included) hole and attach the Roller Fairlead (not
included) to the mounting channel with the bolts provided, and guide the wire
cable through the rollers. (See Fig.2)
Mounting bolts must be SAE grade 5 or better and torque to 34 lbs.
3. Turn the winch up-side-down; insert 4 Cap Screws with Flat Washers
(Part#500019 & Part# 500021) into the holes of the winch as showed in Fig. 3.
4. Place the Mounting Channel (not included) on the winch as shown in Fig. 4.
Make sure the winch is centered in the middle of the mounting channel.
Disengage the clutch by moving the Cam Ring to the “Out” position. Release
the wire cable and pull through the slot in the front of the channel.
5. Attach using the 4 x M10 Nuts with Lock Washers (Part# 500022 & Part#
500020) into the hole. (See Fig. 5)

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6. Attach the clevis hook and hand strap. (See Fig. 6, Fig. 7)
7. Connect the battery leads. NOTICE: BATTERY SHOULD BE A MINIMUM OF
650CCA FOR WINCH TO FUNCTION PROPERLY. Connect the red (positive)
lead from the solenoid to the positive (+) terminal of the vehicles 12 volt
battery. Connect the black (negative) lead from the solenoid to the negative
(-) terminal of the battery.
Caution Battery cables should not be drawn taut. Leave some
slack for cable movement.
8. Attach the hand held remote lead to the winch and test for proper operation.
(See Fig. 9)
9. Check for proper drum rotation. Pull and turn the clutch knob to the “out”
position (Free spooling). Pull out some cable from the drum, and turn the
clutch knob to the “in” position to engage the gears. Press the cable out
button on the power switch. If the drum is turning and releasing more cable
then your connections are accurate. If the drum is turning and collecting
more cable then reverse the leads on the battery. Repeat and check rotation.
Fig. 1 Fig. 2

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Fig. 3 Fig. 4
Fig. 5 Fig. 6
Fig. 7 Fig. 8
Fig. 9

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SAFETY PRECAUTIONS
WARNING
READ, STUDY, AND FOLLOW ALL INSTRUCTIONS BEFORE
OPERATING THIS DEVICE.
WARNING – DO NOT EXCEED RATED CAPACITY.
WARNING – Do not use winch for lifting or moving people or animals.
WARNING – A minimum of 5 wraps of cable around the drum barrel is
necessary for pulling and holding the rated load. The cable clamp is not
designed to hold the load without 5 wraps of cable around the barrel.
WARNING – Keep yourself and others at a safe distance. Stand to the side of
the cable when under tension.
WARNING – The wire rope may break before the motor stalls. For heavy
loads at or near rated capacity, use a pulley block/snatch block (not included)
to reduce the load on the wire rope.
WARNING – Never step over a cable, or near a cable under load.
WARNING – Do not move the vehicle to pull a load (towing) on the winch
cable. This could result in cable breakage.
WARNING – Disconnect the remote control and battery leads when not in use.
WARNING – Avoid “shock loads” by using the control switch intermittently to
take up the slack in the wire rope. “Shock loads” can far exceed the rate
capacity for the wire rope and drum.
WARNING – When re-spooling the cable, ensure that the cable spools in the
under-wind position with the cable entering the drum from the bottom, not the
top. To re-spool correctly, and while wearing gloves, keep a slight load on
the cable while pushing the remote button to draw in the cable. Walk toward
the winch not allowing the cable to slide through your hands. Do not let your
hands get within 12” of the winch while re-spooling. Turn off the winch and
repeat the procedure until a few feet of cable is left. Disconnect the remote
control and finish spooling by rotating the drum by hand with the clutch
WARNING

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disengaged. Keep hands clear of the fairlead and drum while the winch is
under power.
WARNING – Do not use as a hoist. Do not use for overhead lifting.
CAUTION – Use gloves to protect hands when handling the cable. Never let
the cable slide through your hands.
WARNING – Don’t wrap cable around any object and hook back onto itself.
Apply blocks to the wheels of the vehicle when on an incline.
No modifications, alterations, or deviation to the winch are authorized by the
manufacturer and shall not be made.
Duration of winching pulls should be kept as short as possible. If the motor
becomes uncomfortably hot to the touch, stop winching immediately and let it
cool down for a few minutes. Do not pull for more than one minute at or near the
rated load.
CAUTION - If the motor stalls do not maintain power to the winch. Electric
winches are designed and made for intermittent use and should not be used in
constant duty applications.
CAUTION - Never release the free-spool clutch when there is a load on the
winch.
CAUTION - Use the hand strap when handling the hook for spooling or un-
spooling the wire cable.
WARNING - Failure to heed these warnings may result in personal injury
and/or property damage.

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GENERAL TIPS FOR SAFE OPERATION
•The C50079 is rated at 5,000 lbs. capacity (Max) on the first layer when
spooling the first cable layer on the drum. Overloads can damage the
winch motor or wire cable. For loads over 5,000 lbs., we recommend the
use of the pulley block/snatch block (not included) to double the wire
cable line. This will aid in two ways: a) reduce the number or cable layers
on the drum, as well as: b) reduce the load on the wire cable by as much
as 50%. When doubling the line back to the vehicle, attach to the frame or
other load bearing part.
•The vehicle engine should be kept running during operation of the winch
to minimize battery drain and maximize power and speed of the winch. If
the winch is used for a considerable time with the engine off the battery
may be drained and too weak to restart the engine.
•Get to know your winch before you actually need to use it. We recommend
that you set up a few test runs to familiarize yourself with rigging
techniques, the sounds your winch makes under various loads, the way
the cable spools on the drum, etc.
•Inspect the wire cable and equipment before each use. A frayed or
damaged cable shall be replaced immediately. Use only manufacturer’s
identical replacement cable with the exact specifications.
•Inspect the winch installation and bolts to ensure that all bolts are tight
before each operation.
Never connect the cable back to itself. This will cause
cable damage. Always use a snatch block, sling or chain of suitable strength
as shown in the illustrations.
WARNING

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•Store the remote control inside your vehicle in a place that it will not be
damaged.
•Any winch that appears to be damaged in any way, is found to be worn, or
operates abnormally MUST BE REMOVED FROM SERVICE UNTIL
REPAIRED. It is recommended that the necessary repairs be made by a
manufacturer’s authorized repair facility.
•Pull only on areas of the vehicle as specified by the vehicle manufacturer.
•Only attachments and/or adapters supplied by the manufacturer are to be
used.

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RIGGING TECHNIQUES
Self Recovery
Locate a suitable anchor such as a strong tree trunk or boulder.
Always use a sling (not included) as an anchor point. CAUTION - Do
not attach the clevis hook back onto the cable as this could cause
damage to the cable.
See Fig 3.1.
A roller fairlead (not included) will help guide the wire cable and reduce
binding on short side pulls. Do not winch from an acute angle as the
wire rope will pile up on one side of the drum causing damage to wire
rope and the winch. See Fig 3.2.
Short pulls from an angle can be used to straighten the vehicle. Long
pulls should be done with the wire rope at a 90° angle to the
winch/vehicle.
When pulling a heavy load, place a blanket or jacket over the wire rope
five or six feet from the hook. In the event of a broken cable it will
dampen the snap back. For additional protection open the hood of the
vehicle as shown in Fig 3.3.
For pulls over 3,200lbs., we recommend the use of a snatch
block/pulley block (not included) to double line the wire rope. See Fig
3.4. This reduces the load on the winch and the strain on the cable by
approximately 50%.
WARNING - Never use your winch for overhead hoisting or for
lifting people or moving people.
Fig 3.1
Fig 3.2
Fig 3.3
Fig 3.4
Fig35

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WINCHING TECHNIQUES A-Z
a. Take time to assess your situation and plan your pull.
b. Put on gloves to protect your hands.
c. Disengage the clutch to allow free-spooling and also save battery power.
d. Attach the hand strap to the clevis hook.
e. Pull out the wire cable to your desired anchor point using the hand strap.
f. Secure the clevis hook to the anchor point (sling, chain, or snatch block).
Do not attach the hook back onto the wire rope.
g. Engage the clutch.
h. Connect the remote control to the winch. If you are going to control the
winch from inside your vehicle, then pass the remote through an open
window to avoid the wires being pinched in the door.
i. Start your engine to ensure power is being replenished to the battery.
j. Draw up slack in the cable. Once the cable is under tension stand clear.
Never step over the wire cable.
k. Double check your anchors and make sure all connections are secure.
l. Inspect the wire cable. Make sure there are at least 5 wraps of wire cable
around the winch drum.

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m. Drape a blanket or jacket over the wire cable approximately 5 to 6 feet from
the hook. Open the hood for added protection.
n. Clear the area. Make sure all spectators are at a safe distance and that no
one is directly in front or behind the vehicle or anchor point.
o. Begin winching. Be sure that the wire cable is winding evenly and tightly
around the drum. The vehicle that is being winched can be slowly driven
to add assistance to the winching process. Avoid shock loads; keep the
wire cable under consistent tension.
p. The vehicle to be winched should be placed in neutral and the emergency
brake released. Only release the brake pedal when under full tension.
Avoid shock loads to the winch. This can damage the winch, cable, and
vehicle.
q. The winch is meant for intermittent use while under a full load with a single
line rig. Do not reel in the winch for more than one minute without letting
the motor cool down for a few minutes. Afterwards, you may resume the
winching operation.
r. The winching operation is complete once the vehicle is on stable ground
and is able to drive under its own power.
s. Secure the vehicle. Be sure to set the brakes and place the vehicle in park.
t. Release the tension on the wire cable. The winch is not meant to hold the
vehicle for long periods of time.
u. Disconnect the wire cable from the anchor.

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v. Rewind the wire cable. Make sure that any wire already on the drum has
spooled tightly and neatly. If not, draw out the wire and re-spool from the
point where the rope is tight.
w. Keep your hands clear of the winch drum and fairlead as the wire rope is
being drawn in.
x. Secure the hook and hand strap.
y. Disconnect the remote control and store in a clean, dry place.
z. Clean and inspect connections and mounting hardware for next winching
operation.

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MAINTENANCE
Lubrication
1. All moving parts within the electric winch have been lubricated using high
temperature lithium grease at the factory. No internal lubrication is
required.
2. Lubricate cable assembly (4) periodically using a light penetrating oil.
Cable Assembly Replacement
It is recommended that any such modifications be performed by a
manufacturer’s authorized repair facility, and that only manufacturer-supplied
parts be used.
1. Move cam ring to the “out” position.
2. Extend cable assembly to its full length. Note how the existing cable is
connected to the inside of the drum.
3. Remove the old cable assembly and attach new one.
4. Retract the cable assembly onto the drum being careful not to allow
kinking.

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TROUBLE SHOOTING
SYMPTOM POSSIBLE CAUSE SUGGESTED ACTION
Motor does not
turn on
-Switch Assembly not
connected properly
-Loose battery cable
connections
-Solenoid malfunctioning
-Defective Switch
Assembly
-Defective motor
-Water has entered motor
-Insert Switch Assembly all the way into
the connector.
-Tighten nuts on all cable connections.
-Battery should minimum 650CCA.
-Tap solenoid to loosen contacts. Apply
12 volts to coil terminals directly. A
clicking indicates proper activation.
-Replace Switch Assembly.
-Check for voltage at armature port with
Switch pressed. If voltage is present,
replace motor.
-Allow to drain and dry. Run in short
bursts without load until completely dry.
Motor runs but
Cable drum does
not turn
-Cam Ring (clutch) not
engaged
-Move Cam Ring to the “in” position. If
problem persists, a qualified technician
needs to check and repair.
Motor runs slowly
or without normal
power
-Insufficient current or
voltage
-Battery weak, recharge. Run winch with
vehicle motor running.
-Loose or corroded battery cable
connections. Clean, tighten, or replace.
Motor overheating -Winch running time too
long
-Allow winch to cool down periodically.
Motor runs in one
direction only
-Defective or stuck
solenoid
-Defective Switch
Assembly
-Tap solenoid to loosen contacts.
-Repair or replace solenoid.
-Replace Switch Assembly.

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WINCH ASSEMBLY DRAWING
8
4
3
2
13
5
6
17
7
12
1
13
14
15
13
11
10
17
9
34
35
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
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WINCH PARTS LIST
Item# Part # Qty Description
1 500100 1 Gear Carrier Assembly –Input
2 500200 1 Gear Carrier Assembly –Intermediate
3 500300 1 Gear Carrier Assembly –Output
4 500400 1 Cable Assembly
5 500500 1 Motor/End Bearing Assembly
6 500600 1 Break / Shaft Assembly
7 500700 1 Solenoid Assembly
8 500800 1 Switch Assembly
9 500900 1 Drum Assembly
10 500001 6 Screw M4x12
11 500002 1 Cover - Gear Housing
12 500003 1 Gasket
13 500004 3 Thrust Washer
14 500005 1 Thrust Disc
15 500006 1 Gear-input, Sun
17 500008 1 Bushing-Drum
18 500007 1 Gear-Intermediate, Sun
20 500009 1 Gear-output, Sun
21 500010 1 Cap screw M6x10
22 500011 1 Hexangular Shaft
23 500012 6 Cap screw M6x20
24 500013 1 Retainer-Ring
25 500014 1 Gear-Ring
26 500015 1 Cam Ring
27 500016 1 Locking Ring
28 500017 6 Spring
29 500018 1 End Bearing
30 500019 6
Cap Screw M10x35
31 500020 6 Lock Washer Ø10
32 500021 6 Washer-Flat Ø10
33 500022 6 Nut M10
34 500023 4 Nut M6
35 500024 4 Cap screw M6x25

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16
7
6
5
2
4
3
1
10
9
8
13
11
12
14
15
24
29
21
17
18
19
20
23
3
22
28
27
26
25